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ArcelorMittal USA World Class Equipment Reliability Project

Project Summary

Project
ArcelorMittal USA formed a core team of members from 12 operating facilities who were trained by Bentley consultants in reliability principles, methodologies, and technology and then deployed as onsite team leaders to launch its World Class Equipment Reliability (WCER) initiative. To effectively implement and manage the scope of the WCER program, ArcelorMittal installed Bentley’s AssetWise Performance Management (APM) software with a custom interface to AssetPoint’s Tabware computerized maintenance management system.

Solution
Once the core team was trained and the AssetWise software installed, ArcelorMittal piloted its WCER program at Burns Harbor Hot Strip Mill (HSM), forming, and training intensively, a dedicated HSM WCER team to focus on and apply Bentley’s asset performance management processes, practices and methodologies. The success of this pilot was instrumental in implementing the same WCER approach at 10 key U.S.A. operating facilities. To expedite implementation and monitor performance, ArcelorMittal leveraged Bentley’s cloud libraries and single database across all sites, and developed key performance indicators to measure results.

Outcome
The WCER HSM pilot run saved USD 2.1 million within one year. Improvement in equipment inspections and production assets saved almost USD 1.3 million in unplanned downtime. Improved HSM work ratio to reduced asset downtime saved USD 400,000 in energy consumption, while enhanced efficiency of corrective work during plant shutdowns resulted in manpower savings of almost USD 400,000 annually. The benefits of the WCER program at HSM translated to its successful implementation in 10 other facilities, resulting in a cumulative savings in excess of USD 14 million.

Software
ArcelorMittal installed Bentley’s AssetWise APM software with a custom interface to AssetPoint’s Tabware CMMS, providing an operational, informational platform for all U.S. operations. AssetWise provided ArcelorMittal with current, accurate information from equipment inspections, which was instrumental in improving the efficiency of corrective action work performed during scheduled plant shutdowns. Bentley’s cloud libraries enabled ArcelorMittal to expedite the implementation of the same Bentley APM process, practices, methodologies, and technologies across all sites.

Outcome/Facts:

Using a single database and Bentley’s cloud libraries allowed the team to efficiently share information, expediting implementation across all sites.